NEYVELI LIGNITE CORPORATION LIMITED (NLC LTD) · PDF filetechnical specification for chain...

NEYVELI LIGNITE CORPORATION LIMITED (NLC LTD)

NEYVELI NEW THERMAL POWER PROJECT 2x500 MW LIGNITE FIRED UNITS AT NEYVELI

(TURBINE GENERATOR PACKAGE)

PROJECT SPECIFIC

TECHNICAL SPECIFICATION FOR CHAIN PULLEY BLOCK

SPECIFICATION NO.: PE-TS-402-563-A001

BHARAT HEAVY ELECTRICALS LTD

POWER SECTOR PROJECT ENGINEERIING MANAGEMENT NOIDA INDIA

Title TECHNICAL SPECIFICATION FOR

CHAIN PULLEY BLOCK 2X500 MW NNTPS (TG)

Specification no.: PE‐TS‐402‐563‐A001 Rev. 00Date: JAN 2015Sheet 1 of 1

INDEX

S.N. VOLUME SECTION DESCRIPTION PAGE NO.1.0 IIB Section‐A Scope of Enquiry 1 2.0 IIB Section‐B Project Information 3 3.0 IIB Section‐C Specific Technical Requirement 6 4.0 IIB Section‐C Manufacturing Quality Plan 105.0 IIB Section‐C Annexure‐IV Painting Procedure / Color Scheme 146.0 IIB Section‐D General technical requirements 387.0 IIB Section D Data sheet‐A 418.0 IIB Section D Master drawing list and submission schedule

(Annexure V) 44

Volume III 9.0 III Pre‐bid clarification schedule 4710.0 III Schedule of deviation 4811.0 III Compliance cum confirmation certificate 4912.0 III Documents to be submitted along with bid 5013.0 III Unpriced schedule 51

TECHNICAL SPECIFICATION FOR

CHAIN PULLEY BLOCK

2X500 MW NNTPS (SG)

SPECIFICATION NO. PE-TS-402-563-A001

VOLUME - IIB

SECTION - A

REV 00 DATE JAN 2015

PE

M-6

666-

0

VOLUME - IIB

SECTION – A

SCOPE OF ENQUIRY

Page 1 of 52


CHAIN PULLEY BLOCK

2X500 MW NNTPS (SG)


VOLUME - IIB

SECTION - A


PE

M-6

666-

0

SCOPE OF ENQUIRY

1.1 The specification is intended to cover design, engineering, manufacturing, inspection and testing, painting, supply/ delivery duly packed at FOR site including erection & commissioning spares, maintenance tools & tackles, all accessories (isolating switch and power cable from isolating switch to DSL rails) including freight in line with drawings/ documents/ test procedures approved by BHEL/ Customer for CHAIN PULLEY BLOCK.

1.2 The contractor shall be responsible for providing all material, equipment & services, which are required to fulfil the intent of ensuring operability, maintainability, reliability and complete safety of the complete work covered under this specification, irrespective of whether it has been specifically listed herein or not. Omission of specific reference to any component / accessory necessary for proper performance of the equipment shall not relieve the contractor of the responsibility of providing such facilities to complete the supply of CHAIN PULLEY BLOCK.

1.3 It is not the intent to specify herein all the details of design and manufacture. However, the equipment shall conform in all respects to high standards of design, engineering and workmanship and shall be capable of performing the required duties in a manner acceptable to purchaser who will interpret the meaning of drawings and specifications and shall be entitled to reject any work or material which in his judgement is not in full accordance herewith.

1.4 The extent of supply under the contract includes all items shown in the drawings, notwithstanding the fact that such items may have been omitted from the specification or schedules. Similarly, the extent of supply also includes all items mentioned in the specification and /or schedules, notwithstanding the fact that such items may have been omitted in the drawing.

1.5 The general term and conditions, instructions to tenderer and other attachment referred to elsewhere are made part of the tender specification. The equipment materials and works covered by this specification is subject to compliance to all attachments referred to in the specification. The bidder shall be responsible for and governed by all requirements stipulated herein.

1.6 While all efforts have been made to make the specification requirement complete & unambiguous, it shall be bidders’ responsibility to ask for missing information, ensure completeness of specification, to bring out any contradictory / conflicting requirement in different sections of the specification and within a section itself to the notice of BHEL and to seek any clarification on specification requirement in the format enclosed under Vol-III of the specification within 10 days of receipt of tender documents. In absence of any such clarifications, in case of any contradictory requirement, the more stringent requirement as per interpretation of Purchaser/Customer shall prevail and shall be complied by the bidder without any commercial implication on account of the same. Further in case of any missing information in the specification not brought out by the prospective bidders as part of pre-bid clarification, the same shall be furnished by Purchaser/ Customer as and when brought to their notice either by the bidder or by purchaser/ customer themselves. However, such requirements shall be binding on the successful bidder without any commercial & delivery implication.

1.7 The bidder’s offer shall not carry any sections like clarification, interpretations and /or assumptions.

1.8 Deviations, if any, should be very clearly brought out clause by clause in the enclosed deviation schedule along with cost of withdrawal; otherwise, it will be presumed that the vendor's offer is strictly in line with NIT specification.

1.9 In case all above requirements are not complied with, the offer may be considered as incomplete and would become liable for rejection.

1.10 Unless specified otherwise, all through the specification, the word contractor shall have same meaning as successful bidder /vendor and Customer/ Purchaser/Employer will mean BHEL and /or customer including their consultant as interpreted by BHEL in the relevant context.

Page 2 of 52

VOLUME - IIB

SECTION – B

PROJECT INFORMATION (PROJECT SPECIFIC)

Page 3 of 52

��

��

��

� ��!��"��

�#$ �%&'()*+&�(%�

$-� � �.�� /��'� -�� 0�� '�� 0��% �� -��00�� -� �� '�� '/ � ��1��%��2�� '��/��' ��/� �3�� 0�'/��'��'� � ��-�� /��'�2��*��0��%�-� �� -�� 0% ��'4�/��%�' ��0/�5��

�#� �(,�'��-%&� �&��

$-��4� �'�� '��0��/��'�%��-��40��)� �'�6� ��0* �7��89� ��6��'��%�� $�:��5��0$�:��

�#. �'(/�+&�0� �&��%1('2-&�(%��

;�<� �4�� =�� -�� > ��/��'� �� 9� �� 0 ;��9�0<% ��/��'�% 9�00�'� � �� % $��'��0�:��%��0��

;��<� 9��'�� > ��-��/� �� ' ;��0��< �� 0;��<%�� %�9�%��0��

;��<� � �.��$�'� > #5!��13��/��'� ��4 $-� ��' ��4� :��;��$�:<

;��<� �� > #�� 2�� - �� 9-�� 0 !� 2��-�4��9�00�'� �

;�<� ��0� > ��?@A��B��?!A��B�

;��<� ��0� > C �#"A��B��C �#CA��B�

;��<� �'��1:� > D"C�

;��<� �� '4�/:�� > ��/��'�%

;�5<� �� :�� > 9-��%��0��#��2�

;5<� �� (� �� > 9-��%��0��#��2�

;5�<� ��0 (��=(�� - �:��

> 9��0�/9-��$-��.�� E@!9 ��0 ��0 �� -��-4�/ ��9�00�'� � + &� �0-��-�'�� /��'��*�- �E ��0 �� -��- 4�/ ��0� � �4�'' ��0 � ��9 �4��-�� 0��$-�� - ��0�� 5��'/�! 2�� 9-��+$-��.�� E +@!9 ��0

;5��<� �&��&�('(�(3�+-��-&-�

• 1�5��

> @#�F�9

Page 4 of 52

��

��

• 1��(��$��

> #"� �9

• 3��'�� > # �9

• 1�5��'��E��0�/ > #G��-��-��:��

• 1��'��E��0�/ > #?G��-��-��1�/

• ��'' > (��#"!�C��''/;�� <

• 3��00� �� > :��-3�� -��0� ��

• 3��0:��0 > C�# 2�=- ;��5�� 0�0<@�?2�=- ;�� 4��0��0<

• :��/ > (� �� :> �F ? ;�� @< ;H��<�� >��C!�

;5��<� �� 2�� -� ��

> ��'��-%$��'

IIIII

Page 5 of 52


CHAIN PULLEY BLOCK

2X500 MW NNTPS (TG)


VOLUME - IIB

SECTION - C


PE

M-6

666-

0

VOLUME - IIB

SECTION – C

SPECIFIC TECHNICAL REQUIREMENT

Page 6 of 52


CHAIN PULLEY BLOCK

2X500 MW NNTPS (TG)


VOLUME - IIB

SECTION - C


PE

M-6

666-

0

1.0 SCOPE OF WORK

1.1 The specification is intended to cover design, engineering, manufacture, inspection and testing at vendor's / sub-vendor’s works, painting, forwarding, proper packing and shipment and delivery at site as required on FOR site basis, demonstration test at vendor’s works (as mentioned elsewhere in the specification) of CHAIN PULLEY BLOCK as per details in different sections / volumes of this specification for 2X500 MW NNTPS (SG)

1.2 The equipment to be furnished by the bidder for the chain pulley blocks of different capacity and lift

as specified in Annexure-I along with all accessories. 1.3 The chain pulley blocks offered shall have technical parameters as per the Data Sheet A enclosed

herewith in section –D of Vol IIB 1.4 Any equipment/accessories not specified herein but required to make the equipment complete and

efficient shall also be under bidder's scope of work. The following shall be in the bidder’s scope of work.

a. Chain pulley blocks with/without traveling trolleys as per the Annexure-I. b. Maintenance Tools and Tackles as given at 4.0 c. Packaging. d. O&M manuals, drawings and documents etc. e. Inspection & testing of Chain Pulley Blocks as per QAP approved by BHEL /Customer during

detail engineering. Prime inspection agency shall be BHEL / End Customer. Equipment being supplied shall be strictly in accordance with nomenclature & technical specification. Any additional testing requirement at any stage of inspection deemed necessary by Customer/BHEL shall be carried out without any commercial or technical or delivery implication.

2.0 TESTING AND INSPECTION 2.1 As per standard quality plan enclosed. Any additional inspection & testing requirement / CHP

(customer’s hold point) deemed necessary by customer/BHEL during detailed engineering shall also be complied with without any commercial or delivery implication.

2.2 Chain pulley block shall be completely assembled at manufacturer’s works and minimum following

tests shall be conducted at works

a. Over load test b. Rated load test c. Other tests as per IS-3832.

2.3 The scope of inspection shall include but not limited to the following:

i. Material identification / co-relation for important items like hook, load chain, hand chain, wheels, ratchet and pawl etc.

ii. Hardness for pawl and ratchet iii. Dye penetration test/ UT test for hooks iv. Operational test including operational effort, velocity ratio etc. v. Proof load test upto 1.5 times of working load limit. vi. Dimensional check of hook vii. Marking

3.0 WORKS EXCLUDED 3.1 Supply of monorail for traveling trolley of chain pulley blocks. 4.0 MAINTENANCE TOOLS AND TACKLES Page 7 of 52


CHAIN PULLEY BLOCK

2X500 MW NNTPS (TG)


VOLUME - IIB

SECTION - C


PE

M-6

666-

0

A complete unused one set of special purpose maintenance tools & tackles and accessories along with detailed instructions for maintenance and manual operation shall be supplied. Tools shall be of suitable sizes for maintenance of Chain Pulley Block of each type and capacity. Each tool and wrench shall be stamped so as to be identified easy for its use and size. The tools shall be supplied in steel toolbox and with a copy of instruction manual. The items supplied shall be of the best quality, specially protected against rusting. The following shall be provided as minimum requirement.

i. Adjustable spanner One (1) ii. Wrench spanner One (1) iii. Oil gun One (1) iv. Set of Screw driver Min 6 nos. (of different sizes suiting various types

. and capacities of Chain Pulley Blocks) v. 2 lb hammer with wooden One (1) handle vi.. Grease Gun One (1)

Note: All maintenance tools & tackles are to be supplied in a tool box.

Any other item required for maintenance shall also be provided. 5.0 Mandatory Spares –

NA

6.0 DRAWINGS/DESIGN DOCUMENTS FOR SUBMISSION (during detailed engineering) A. For Approval

a. G.A. drawing showing clearances, assembly, cross section details, materials of construction, lifts & approaches etc.

b. Quality plan c. Test certificates & reports on various shop tests.

7.0 NO.OF DRAWINGS/DOCUMENTS FOR SUBMISSION (as per attachment in Volume IIB,

Section C, Annexure V) 8.0 DEVIATIONS 8.1 If the offer submitted has got any deviations from technical specification in the tender document.

Bidder shall tabulate the same in the ‘Schedule of Deviations” furnishing full particulars of such deviations. Deviations are to be furnished with mention to specific clause numbers notes/ comments e.g. “Refer to forwarding letter” etc. is not acceptable. Cost of withdrawal of deviations to be put against each deviation.

8.2 If there are no deviations from the tender document, bidder shall indicate so. 9.0 FUNCTIONAL TESTS 9.1 The chain pulley blocks along with other accessories shall be guaranteed for the rated capacity.

The minimum following tests shall be conducted at works – Overload test, rated load test and other tests as per IS-3932. Pull on the hoist and trolley shall not increase during full load operation.

9.2 The bidder shall have full responsibility for the safe and efficient operation of the chain pulley

blocks and traveling trolley with associated accessories as a single unit. 9.3 If the shop performance tests indicate the failure of any of the components to achieve the

functional performance, the deficiency shall be made good at bidder's cost. Page 8 of 52


CHAIN PULLEY BLOCK

2X500 MW NNTPS (TG)


VOLUME - IIB

SECTION - C


PE

M-6

666-

0

9.4 Performance tests shall be carried out each time after the rectification modification is carried out. 10.0 MAKE OF SUB-VENDOR ITEMS (*) Following makes of bought out items shall be considered: Steel SAIL/IISCO/TISCO

Steel Forgings Chowdhary/Western India Forgings/ Hindustan Steel Forgings/ Ruby Forgings or as approved by BHEL. Hook Herman Mohata/Moozumdar & Moozumdar/ Steel .

Forgings/ Karachiwala/Smriti/Nasik Forge. Brakes BHEL approved make (*) The sub-vendor list is indicative and will be subject to customer approval during detail engineering of the package without any commercial implication on account of the same. 11.0 PAINTING SPECIFICATION As per attached painting specification in Annexure IV of this volume. 12.0 Packing In general packing shall be wooden box packing.

SCOPE OF CHAIN PULLEY BLOCKS

ANNEXURE-1 A Chain pulley blocks (CPB)

S No. Area Type Capacity (T)

Lift( m) Qty Remark

1 TG BLDG. Sump Pumps CPB + TT 1 10 4

2 Lube Oil Unloading IN B-C Bay CPB + TT 1 10 1

3 AHU ROOM AT 8.5 M CPB + TT 2 6 1 4 AHU ROOM AT EACH

FLOOR OF SERVICE BLD. CPB + TT 2 6 10

5 AHU ROOM AT 24 M CPB + TT 2 8.5 1 6 AIR WASHER ROOM-1 CPB + TT 2 8.5 2 7 AIR WASHER ROOM-2 CPB + TT 2 8.5 2 8 AIR WASHER ROOM-3 CPB + TT 2 8.5 2 9 AIR WASHER ROOM-4 CPB + TT 2 8.5 2

Page 9 of 52

MANUFACTURER’S NAME & ADDRESS :

MANUFACTURING QUALITY PLAN

ITEM : Chain Pulley Block QP No.: PE-TS-402-563-A001

REV.:0, Date.: JAN 2015, PAGE: 1 OF 4

PROJECT : 2X500 MW NNTPS (TG)

PACKAGE : CHAIN PULLEY BLOCKS

VOL IIB, SEC C

Sr. No.

1.

COMPONENT /

OPERATION

2.

CHARACTERISTICS

3.

CLASS 4.

TYPE OF CHECK

5.

QUANTU

M OF CHECK

6.

REFERENCE DOCUMENT

7.

ACCEPTANCE NORMS 8.

FORMAT OF RECORD 9.

AGENCY

REMARKS

11. M C N

10.

LEGEND: FOR CUSTOMER USE ** M : MANUFACTURER / SUB-CONTRACTOR MANUFACTURER / CONTRACTOR C : BHEL / NOMINATED INSPECTION AGENCY.

N : CUSTOMER

SUB-CONTRACTOR INDICATE “P” PERFORM “W” WITNESS AND “V” VERIFICATION SIGNATURE REVIEWED BY NAME & SIGN OF APPROVING AUTHORITY & SEAL

1

RAW MATERIAL & B/OUT ITEMS:

1.1 HOOKS DIMENSIONS, MA One sample

IS: 15560 IS: 15560 MTC P V V UT FOR SHANK DIA 50MM AND ABOVE CHEMICAL

COMPOSITION, MECHANICAL, PHYSICAL PROPERTIES

MA

LAB ANALYSIS PER LOT

Material specification as per approved drawings

T.C. P

V

V

IDENTIFICATION & COMPLIANCE WITH TC.

MA VISUAL

100% HOOK TC FROM COMPETENT AUTHORITY

IR P

V

V

INTERNAL DEFECTS MA UT 100% ASTM A‐388 (REFER NOTE 1) TC P V V PROOF LOAD TEST MA REVIEW 100% IS 15560 TC P V V NDT AFTER PROOF LOAD MA DPT 100% ASTM E‐165 NO RELEVANT

IDENTIFICATION TC P V V

1.2 LOAD CHAIN ‐ DIMENSIONS ‐ BREAKING STRENGTH ‐ PROOF LOAD ‐HEAT TREATMENT ‐GRADE

MA MA MA MA MA

MEASUREMENT ‐TENSILE TEST ‐TENSILE TEST REVIEW REVIEW

100 % 1/LOT 100% 100% 1/BATCH

IS: 6216 & APPD. DRGS.

IS: 6216 & APPD. DRGS.

IR MTC MTC HT CHART MTC

P P P P P

V V V V V

V V V V V

1.3 RAW MATL. FOR GEAR/ RATCHET PAWL / RATCHET WHEEL

CHEMICAL COMPOSITION, MECHANICAL PROPERTIES

MA

LAB ANALYSIS

ONE SAMPLE PER LOT

MATERIAL SPECIFICATION AS PER

MATERIAL SPECIFICATION AS PER

MTC P

V

V

TC or inspection report for components

Page 10 of 52







VOL IIB, SEC C

Sr. No.

1.

COMPONENT /

OPERATION

2.

CHARACTERISTICS

3.

CLASS 4.

TYPE OF CHECK

5.

QUANTU

M OF CHECK

6.

REFERENCE DOCUMENT

7.

ACCEPTANCE NORMS 8.

FORMAT OF RECORD 9.

AGENCY

REMARKS

11. M C N

10.


N : CUSTOMER


APPROVED DRAWING

APPROVED DRAWING

shall be given.

INTERNAL DEFECTS

MA UT 10% ASTM A‐388 (REFER NOTE 1) IR P V V

1.4.

1.5

LOAD CHAIN WHEELS BEARINGS

‐ CHEMICAL COMPOSITION MECHANICAL PROPERTIES MAKE, TYPE, CATALOGUE NO.

MA MA MA

CHEMICAL MECHANICAL PROPERTIES VISUAL

ONE SAMPLE PER LOT RANDOM

APPD. DRG. APP DRG / MFR”S CATALOGUE

APPD. DRG. APP DRG / MFR”S CATALOGUE

MTC IR

P P

V V

V V

1.6 HAND CHAIN WHEEL CHEMICAL MECHANICAL PROPERTIES

MA CHEMICAL MECHANICAL PROPERTIES

ONE SAMPLE PER LOT

AS PER DRAWING

AS PER DRAWING

MTC P

V

V

1.7 HAND CHAIN GRADE/ DIMENSION MA GRADE DIMENSION

100 % AS PER DRAWING

AS PER DRAWING

MTC P V V

1.8

TROLLEY GEARS, PINION,WHEELS, AXLE

CHEMICAL & MECHANICAL MA LAB ANALYSIS, 100% APPVD DRGS APPVD DRGS IR/TC

P V V

2 IN PROCESS 2.1 RATCHET PAWL /

RATCHET WHEEL ‐HARDNESS

MA

HARDNESS

100%

IS:3832 / APPD DRG.

IS:3832/ APPD. DRG.

IR

P

V

V

Page 11 of 52







VOL IIB, SEC C

Sr. No.

1.

COMPONENT /

OPERATION

2.

CHARACTERISTICS

3.

CLASS 4.

TYPE OF CHECK

5.

QUANTU

M OF CHECK

6.

REFERENCE DOCUMENT

7.

ACCEPTANCE NORMS 8.

FORMAT OF RECORD 9.

AGENCY

REMARKS

11. M C N

10.


N : CUSTOMER


‐SURFACE CRACK

MA DPT

100 %

ASTM E165

NO DEFECT

IR

P

V

V

2.2 GEARS AND PINIONS AFTER MACHINING

SURFACE HARDNESS HEAT TREATMENT, SURFACE CRACK, CASE DEPTH

MA HARDNESS HT CHART, DPT FOR SURFACE CRACK

RANDOM ASTM E 165 FOR DPT

MFG STANDARD NO DEFECT

MFG STANDARD

IR IR

P P

V V

V V

3.0

FINAL INSPECTION

3.1 COMPLETE ASSEMBLY OVERALL DIMENSION

MA

MEASUREMENT 100 %

IS:3832 /APPD DRG

IS:3832 /APPD DRG

IR

P W V

PROOF LOAD TEST

CR

LOAD TEST

100%

‐DO‐

No cracks, flaws & other defects

IR

P W V

LIGHT LOAD TEST

MA

LOAD TEST

100%

IS 3832 IS 3832

IR

P W V

HEIGHT OF LIFT MA MEASUREME NT 100% ‐DO‐ ‐DO – IR

P W V

SWIVELING OF HOOK

MA

VISUAL

100 %

‐DO‐

‐DO‐

IR

P W V

EFFORT MA PULL ON CHAIN 100% ‐DO‐ ‐DO‐ IR

P W V

3.2 PAINTING ‐CLEANING MA VISUAL AT RANDOM

APPROVED APPROVED IR P

‐‐ ‐‐

‐ SHADE & DFT OF PAINT (Blue / Black)

MI VISUAL AT RANDOM

DRAWING/ SPECIFICATION

DRAWING/ SPECIFICATION

IR P

W

‐

Page 12 of 52







VOL IIB, SEC C

Sr. No.

1.

COMPONENT /

OPERATION

2.

CHARACTERISTICS

3.

CLASS 4.

TYPE OF CHECK

5.

QUANTU

M OF CHECK

6.

REFERENCE DOCUMENT

7.

ACCEPTANCE NORMS 8.

FORMAT OF RECORD 9.

AGENCY

REMARKS

11. M C N

10.


N : CUSTOMER


3.3 NAME PLATE VERIFICATION MA VISUAL 100% IR P V

‐‐

3.4 PACKING ‐VERIFICATION MI VISUAL 100% SPECS. SPECS. IR P ‐‐

‐

3.5

REVIEW OF QA DOCUMENTATION

VERIFICATION MA VISUAL 100% APPD. QP APPD. QP V V V

CR – CRITICAL, MA – MAJOR , MI – MINOR NOTE 1: BACK WALL ECHO SHALL BE ADJUSTED TO 100% OF FULL SCREEN HEIGHT IN SOUND (DEFECT FREE) AREA. DEFECT ECHO HEIGHT MORE THAN 20% OF SCREEN HEIGHT SHALL BE TREATED AS UNACCEPTABLE. BACK WALL ECHO SHALL NOT BE LESS THAN 80% OF SCREEN HEIGHT IN ANY CASE. NOTE 2: RECORDS IDENTIFIED WITH TICK SHALL BE ESSENTIALLY INLCUDED IN QA DOCUMENTATION.

Page 13 of 52

2x500 MW, NNTPP, Neyveli

CONTRACT SPECIFICATION

STEAM TURBINE GENERATOR PACKAGE – NTA2

TG, Vol - IIA, Sec - XVII, Painting, NTA2 Page i

VOLUME-IIA

SECTION XVII

PAINTING SCHEME

Page 14 of 52

6044484

Text Box

ANNEXURE IV




TG, Vol - IIA, Sec - XVII, Painting, NTA2 Page ii

TABLE OF CONTENTS

17.1 General ................................................................................................. 343

17.2 Painting For Mechanical & Electrical And Other Equipment, Mechanical Structures,

Piping, Ducts Etc. ................................................................................... 343

17.3 Painting Of Steel Structural Works ............................................................ 364

17.4 Submission Of Painting Schedule .............................................................. 364

Page 15 of 52




TG, Vol - IIA, Sec - XVII, Painting, NTA2 Page 343

17.1 General

17.1.1 This specification covers the materials, tools, facilities and quality requirement for

surface preparation and painting of steel structures, mechanical & electrical

equipments, technological structures, piping, ducts, chutes etc. for 2 X 500 MW

Thermal Power Plant as elaborated in the further text.

This specification will be read in conjunction with other parts/ volumes of the

Tender specification where other related project requirements have been indicated.

The term “Painting” referred herein covers rust preventive, preventive and

decorative coating along with surface preparation of the following areas.

a) All Mechanical equipment, Technological structures, chutes, piping, ducts

etc. unless otherwise specifically indicated in the relevant section

b) Various types of static and rotary equipment inclusive of electric motors

etc.+

c) Steel tanks and vessels

d) Pipe work including trestles, supports, hangers, etc.

e) Metallic duct work such as ventilation ducts, gas ducts including supports,

hangers, etc.

This is a general guideline to the paining scheme to be followed. However, in case

if a specific painting procedure is stipulated in any tendering specification, then

this general guideline will be superseded. Any special case which may arise from

time to time will be dealt with individually on the merits of each case.

17.1.2 Surfaces made of aluminium, brass, bronze, stainless steel, and other corrosion

resistant alloys are not required to be painted unless specified except for

identification bands or for aesthetic purposes.

17.1.3 All machined mating surfaces (e.g. flanges) will be properly cleaned, and will be

provided with protective coating before despatch.

17.1.4 The complete painting scheme for any item includes the following basic activities:

i) Proper surface preparation

ii) Application of primer coats

iii) Application of intermediate coats and

iv) Application of finish coats

All the above coats will be of quality paint products and of approved make as

stipulated in this specification. The scope of work will also include supply of all

paint materials as per specification described herein and of approved quality/

specifications.

17.2 Painting For Mechanical & Electrical And Other Equipment, Mechanical Structures,

Piping, Ducts Etc.

Page 16 of 52





17.2.1 This section covers the painting requirements for the power plant equipment,

structures, piping etc. and any other surface required to be painted.

17.2.2 Codes and Standards

Painting of equipment will be carried out as per the specifications indicated below

and will conform to the relevant IS specification for the material and

workmanship.

The following Indian Standards may be referred to for carrying out the painting job

:

IS:5 : Colours for ready mixed paints and enamels

IS:1303: Glossary of terms relating to paints

IS:2379: Colour code for identification of pipelines

IS:1477: Code of practice for painting of ferrous metals in buildings

(Parts I & II)

IS:2524: Code of practice for painting of non-ferrous metals in buildings

(Parts I & II)

IS:2395: Code of practice for painting of concrete, masonry and plaster

surfaces (Parts I & II)

IS:2338: Code of practice for finishing of wood and wood based

materials (Parts I & II)

IS:6278 : Code of practice for white washing and colour washing

IS:3140: Code of practice for painting asbestos cement building

products

IS:158 : Ready mixed paint, brushing, bituminous, black, lead free, acid,

alkali, water and heat resisting

IS : 2074: Ready mixed paint, air drying, red Oxide Zinc Chrome, priming

IS : 104: Ready mixed paint, brushing, Zinc Chrome, priming

IS : 2932: Enamel , synthetic, exterior (a) undercoating (b) finishing

specification.

17.2.3 Preparation of Surfaces

a) Surface preparation being a pre requisite for any paint application, will be

such as to clean the surface thoroughly of any materials which will be

conducive to premature failure of the paint substrates.

b) All surfaces to be painted will be thoroughly cleaned of all grease, oil, loose

mill scale, dust, rust and any other foreign matter. Mechanical cleaning by

power tool and scrapping with steel wire brushes will be adopted to clear the

surfaces. However, in certain locations where power tool cleaning cannot be

carried out, sand scrapping may be permitted with steel wire brushes and/or

abrasive paper. Cleaning with solvents will be resorted to only in such areas

where other methods specified above have not achieved the desired results.

Page 17 of 52





Cleaning with solvents will be adopted only after written approval of the

Purchaser/ consultant.

c) The workmanship will, in general, be in accordance with IS: 1477-1971.

Surface of all the steel works to be painted will be thoroughly cleaned and

degreased in accordance with IS:1477(Part-I) by means of mechanical and

power tool cleaning or shot blasting. The cleaning quality will conform to

second quality blast cleaning as per BS-4332 or to SA 2.5 of Swedish

Standards Institution SIS 055900. Cleaning of surface will ensure primer

coat is rigidly anchored to the virgin metal surface. Primer paint will be

applied not later than 2-3 hours after preparation of surface, unless

otherwise specified.

17.2.4 The acceptable surface preparation quality/grade are described under each painting

scheme. The procedures covered are solvent cleaning, hand tool cleaning, power

tool cleaning and blast cleaning

a) Solvent cleaning (SP 1) (If applicable)

The surface will be cleaned by wiping, immersion, spraying or vapour

contacting of a suitable solvent or washing with an emulsion or alkaline

solution to remove oil, grease, dirt, old paint, etc. Solvent cleaning will not

remove rust, scales, mill scales or weld flux. Therefore, before application of

paint, solvent cleaning will be followed by other cleaning procedures as

stated below.

b) Hand tool cleaning (SP 2)

The surface will be cleaned by vigorous wire brushing done manually to St-2

quality. This method effectively removes loosely adherent materials, but

would not affect residues of rust or mill scales that are intact and firmly

adherent.

c) Power tool cleaning (SP 3)

The surface will be cleaned by electric or pneumatic tools to St-3 quality.

The tools will be used carefully to prevent excessive roughing of surface

and formation of ridges and burns. This method will remove loosely adherent

materials but would not affect residues of rust or mill scales that are firmly

adherent.

d) Blast cleaning (SP 4)

The surface will be cleaned by impingement of abrasive materials, such as

graded sand at high velocity created by clean and dry compressed air blast.

This method will remove loosely adherent materials as well as adherent

scales and mill scales. Prior to application of blast, heavy deposit of oil and

grease are removed by solvent cleaning and excessive surface scales are

Page 18 of 52





removed by hand tools or power tool cleaning. The surface will be cleaned to

Sa-2 1/2 quality which means that to 95% of surface area is free from all

rust, mill scales and visible residues, foreign materials, etc. The blast

cleaning is not recommended for sheet metal work.

17.2.5 Primer Paints (P)

After the surface is prepared in a manner acceptable to purchaser/ consultant, two

(2) coats of Primer paints will be applied only on dry and clean surfaces. Second

coat of red oxide primer will be applied only after first coat has dried up

completely. Coating of primer will in general conform to IS:2074-92 and will be

applied by brushing to ensure a continuous film without “holidays”.

a) Primer paint P1: (Epoxy based)

A two pack air drying epoxy polyamide resin based red oxide –zinc

phosphate (primer):

b) Primer paint P2 ( Epoxy based)

A two pack air drying epoxy polyamide with zinc dust of at least 92% zinc

dust on the dry film.

Epoxy content ( % wt) 8 to 10

Air drying time About 10 minutes ( touch dry)

2 hours ( hard dry)

Dry film thickness ( DFT/coat) 40 microns ( min)

Temperature resistance Upto 300 deg.C dry heat

c) Primer paint P3 ( Ethyl zinc silicate, EZS, based)

A two pack heavy duty zinc dust rich silicate primer:

Epoxy content ( % wt) 15 to 18

Air drying time About 30 minutes ( touch dry)

Over night (hard dry)

Dry film thickness ( DFT/coat) 30 microns (min)


Page 19 of 52





Total solids (% wt) 84 + 2

Air drying time 16 hours

Density 3.07 + 0.005

Dry film thickness ( DFT/coat) 60 microns ( min)


17.2.6 Intermediate paints (N)

These paints will be applied over primer coats as an intermediate layer to provide

weatherproof seal of primer coats.

a) Intermediate paint N1

A two pack air drying high build epoxy resin based paint with MIO.

Air drying time 6 to 8 hours (touch dry) 7 days

(full cure)

Dry film thickness ( DFT/coat) 80 microns


Compatible with Primer P1

17.2.7 Finish Paint (F)

Finish paint coats will be applied over primer coats and intermediate coats after

proper cleaning and touch up of primed coats. Synthetic enamel paint comprising

of IS:2932-95 will be used for finish coats.

a) Finish paint (F1)

A two pack air drying epoxy polyamide enamel suitably pigmented.

Air drying time 2 to 3 hours (touch dry) 7 days (full

cure)

Dry film thickness (

DFT/coat)

30 microns


Page 20 of 52





Compatible with Primers P1 and P2

Intermediate N1

Colour Generally all shades

b) Finish paint (F2)

A single pack synthetic rubber based enamel paint.

Air drying time 2 hours (touch dry)

24 hours (hand dry)

Dry film thickness ( DFT/coat) 25 microns


Compatible with No primers

Colour Generally all shades

c) Finish Paint F3

A single pack heat resistant silicon Aluminum paint.

Air drying time 3 to 4 hours (touch dry) 24 hours

(hard dry)

Dry film thickness (

DFT/coat)

25 microns (min)

Temperature resistance upto 400 deg.C dry heat

Compatible with Primer paint P3

Colour smooth aluminium

Heat resistant Silicone Aluminium Paint with suitable air drying time as per

IS 13183 Gr I, 25 microns per coat.

d) After cleaning the dust on the dried up primer/ intermediate paint, first coat

of synthetic enamel will be applied. After this first coat dries up hard, the

surface is wet scrubbed cutting down to a smooth finish and ensuring that at

no place the first coat is completely removed. After allowing the water to

get evaporated completely, the second finish coat of synthetic enamel paint

Page 21 of 52





will be applied only after gently removing the gloss of first coat from entire

surface and it is dusted off the surface. The requirement of workmanship will

be as per IS:1477-71.

e) Equipment No. and the name of the equipment will be painted on the surface

of the equipment on visible locations in English. Service of the Pipe/Line

designation with arrow identification for the direction of flow will be painted

on all pipes at visible locations at an interval of 20 metres. Wherever

pipelines are insulated, the service of the piping and arrow mark will be

painted over the clad surface.

f) For painting of structure, equipment, tanks & vessels etc. suggested colour

code is given in clause 17.2.8. For items not specified, the colour code to be

followed for piping will be in line with IS 9404:2002 (Identification of

pipelines used in Thermal Power Plants – Colour Code).

g) For insulated pipeline the finish paint will be applied at that place where

colour band is to be painted on the aluminium sheeting. The finished paint

(colour band) will be of 1m length at that place.

h) Colour band for piping will be applied at these following locations-

• At start and end point.

• At every 10m intervals.

• At every T joints and cross connection of piping.

• At every battery limit of pipeline

• Near valves before connection with the consumer.

i) Width of band

Size of pipe including insulated Pipe line outside

diameter

Width of band

80 mm and below 25 mm

Above 80 mm upto 150 mm 50 mm

Above 200 mm upto 300 mm 75mm

Above 350 mm 100 mm

Page 22 of 52





j) Direction of flow will be indicated by black or white arrow in contrast to the

base colour on the pipeline. Length of the arrow will be minimum 125 mm

and width will be minimum 65 mm. These will be put at an interval of 10 m.

17.2.8 Suggested Colour Codes For Painting of Structures, equipments, tanks & vessels

etc.

SL.

NO.

ITEM/SERVICE COLOUR IS-5 COLUR

(BAND

IS-5

1. Structures,

platforms,

galleries,

ladders and

handrails

Dark

admiralty

grey

632 - -

2. Fans, pumps,

motors,

compressors.

Light grey 631 - -

3. Outdoor

,Stand pipes,

vent pipes

Aluminium - - -

4. Indoor Tanks Aluminium - - -

5. Vessels & all

other

proprietary

equipment

(without

insulation &

cladding)

Light grey 631 - -

6. Tanks (without

insulation and

cladding)

Aluminium

7. Switchgear Light grey 631 - -

8. MCC/ PDB,

Control, relay

panels, Bus

duct

Light grey 631/7078

of

IS:1650

- -

Page 23 of 52





9. Transformers Dark

admiralty

grey

632 - -

10. Machinery

guards

Signal red 537 - -

11. Turbine Golden

Yellow

356

12. Generator &

exciter

Light grey 631

13. Piping (without insulation and cladding)

14 Feed water Sea green 217 Light

brown

410

15 Condensate Sea green 217 Light

brown

410

16 D M Water Sea Green 217 Light

orange

557

17 Soft water Sea green 217 French

blue

166

18 Bearing cooling

water

Sea green 217 French

blue

166

19 Potable &

filtered water


blue

166

20 Service &

clarified water


blue

166

21 Condenser and

Auxiliary

Cooling water


blue

166

22 Service air Sky Blue 101 - -

23 Instrument air blue 101 White -

24 Lubricating oil Light brown 410 Light grey 631

25 Control oil Light brown 410 Light 557

Page 24 of 52





orange

26 Transformer oil Light brown 410 Light

orange

557

27 Hydrogen Canary

yellow

309 Post office

red

538

28 Carbon dioxide Canary

yellow

309 Light grey 631

29 Vacuum pipes Sky blue 101 Black -

30 Drainage Black - - -

31 Stand pipes

and all Vent

pipes

Aluminium - - -

Notes:

Where band colour is specified, same will be provided at 10 meter intervals on

long uninterrupted lines and also adjacent to valves and junctions.

17.2.9 Paint Application

a) Paint will be applied in accordance with manufacturer’s recommendations.

The work will generally follow IS 1477 (Part II) for jobs carried out in India

and SSPC-PA-I or DIN 55928 or equivalent for jobs carried out outside India.

Touch up paint to be applied to cover scratches after erection and assembly

of equipment at site.

b) Paint will not be applied when the ambient temperature is 5 deg. C and

below. Also paint will not be applied in rain, wind, fog or at relative humidity

of 80% and above.

c) Each coat of paint will be continuous, free of pores and of even film

thickness without thin spots. The first coat of finish paint at site will be

applied preferably within three months of the shop paint.

d) Each coat of paint will be dry sufficiently before application of next coat.

e) Surface which cannot be painted but require protection will be given a coat

of rust inhibitive grease according to IS:958-75 or solvent deposited

compound according to IS:1153-75 or IS:1674-60.

Page 25 of 52





f) Surface which will be inaccessible after assembly will receive minimum coats

of specified primer. Surfaced to be in contact with wood, brick or other

masonry will be given one shop coat of the specified primer.

g) Parts of steel structure to be embedded in concrete will be given a protective

coat of Portland cement slurry immediately after fabrication and thoroughly

cleaning the surfaces from grease, rust, mill scales etc. No paint will be

applied on this part.

h) The Contractor will furnish paint manufacturer’s test report or technical data

sheet pertaining to the paint selected. The data sheet will indicate among

other things the relevant standards, if any, composition in weight percent of

pigments, vehicles, additives, drying time, viscosity, spreading rate, flash

points, methods of application quality of surface preparation required,

corrosion resistance properties and colour.

i) Rust preventive coating will be given to HSFG bolt and nut threads.

j) Machined surfaces / weld edges will be applied with a coating of temporary

rust preventive oil.

k) All threaded and other surfaces of foundation bolts and its materials,

insulation pins, anchor channels, sleeves will be coated with temporary rust

preventive fluid and during execution of civil works; the dried film of coating

will be removed using organic solvents.

l) The temporary rust preventive coating that already been applied on any

components, tubes, pipes etc., will be removed by suitable solvents/ heating

to 350-400 Deg.C for an hour before primer paint application-but, in case, it

will be ensured that the minimum surface cleanliness required for primer

paint application will be Sp2 (equivalent to hand tool cleaning).

m) All weld edge preparation for site welding will be applied with one coat of

weldable primer.

n) For internal protection of pipes/tubes, VCI pellets will be used at both ends

after sponge testing and ends capped. VCI pellets will not be used for SS

components and composite assemblies.

o) Wherever inside surfaces of ducts need protection till erection, two coats of

red oxide zinc phosphate primer ( P1) paint to IS 12744 to a DFT of 60

microns will be applied after power tool cleaning.

17.2.10 Painting scheme

a) For a complete painting scheme of any item being painted, all types of paints

are to be procured from the same manufacturer as approved by the

purchaser.

b) The painting scheme to be followed for various mechanical/ electrical

equipment / structures is briefly given below for guidance to the Contractor.

Page 26 of 52





Legend

SP Surface preparation quality

P Primer Paint

2P1 stands for Two (2) coats of primer paint type P1

N Intermediate paint

1N 1 One (1) coat of intermediate paint type 1

F Final Paint

2F1 stands for Two (2) coats of finish paint type F1

DFT Dry film thickness

CRT Clean and retouch

Sa - 2.5 Quality of surface cleaning (i.e. 95 % of the

surface area is free from all rust, mill scales and

visible residues, foreign materials etc.

c) Painting Scheme

Sl

no.

Description Surface

Preparati

on

Painting Scheme Total

DFT in

micron At shop At site

1. Steel Structure Sa 2½ 2P1+1N1 2F1 200

2. Mechanical

equipment (temp.

not over 80 deg.

C) Both static and

rotary equipment

Sa 2½ 2P1+1 N1 2F1 200

3. Equipment with

hot surfaces

(temp. upto 400

Sa 2½ 2P2 2F2 130

Page 27 of 52





deg. C)

4. Equipment with

hot surfaces

(temp. above 400

deg.C)

Sa 2½ 2P3 2F3 170

5. Non insulated

pipe/ duct

works - Tempera

ture not over 80

°C

- Temperature

upto 200 °C

- Temperature

upto 400 °C

Sa 2½

2P1+1N1

2P2

2P3

2F1

2F2

2F3

200

50

170

6. Insulated

pipe/duct works

St3 2 coats of

Alkyd Red

Oxide Zinc

Phosphate

primer to IS

12744 –

DFT 30µ/

coat

Not

requir

ed

60

7. Condensate

piping, ACW,

DMCW, service

water, potable

water and minor

structures etc.

Hand

tool/

Power

tool

cleaning

to SSPC-

SP2

2 coats of

HB

Chlorinated

rubber

based red

oxide zinc

phosphate

primer each

50µ

2

coats

of

Chlori

nated

rubber

based

finish

paint

each

160

Page 28 of 52





30µ

PAINTING SCHEME

(METALLIC STRUCTURAL WORKS)

SURFACES TO BE

PAINTED

SURFACE

PREPARA

TION

PAINTING SCHEME

PRIMER

AT SHOP

INTERM

. AT

SHOP

FINISHIN

G AT SITE

1) CARPENTRY

ANCHOR PLATES

AND PIPELINE

SUPPORT

- OUTSIDE SA 2.5 2P1 1N1 2F1

- INSIDE SA 2.5 2P1 1N1 2F1

2) BRIDGE CRANE

- STRUCTURE

FOR BEAMS

SA 2.5 P1 +

P1(S)

1N1 (S) 2F1

- TROLLEY SA 2.5 2P1 1N1 2F1

3) HOISTS AND

MONORAILS

- MONORAILS SA 2.5 2P1 1N1 2F1

- HOISTS SA 2.5 2P1 1N1 2F1

PAINTING SCHEME

(THERMAL CYCLE)

Page 29 of 52





SURFACES TO BE

PAINTED

SURFACE

PREPARATI

ON

PAINTING SCHEME

PRIME

R AT

SHOP

INTER

M. AT

SHOP

FINISHI

NG AT

SITE

1) INSULATED PIPE LINE

AND VALVES

STEAM SA 2.5 2P1/2P

2/2P3

-- --

FEEDWATER SA 2.5 2P1/2P

2/2P3

-- --

DEAERATOR AND FEED

TANK

FEED TANK

- INSIDE

- OUTSIDE

SA 2.5

SA 2.5

Temporary rust preventive

paint

2P3 or 2 coats of Heat

resistant aluminium paint.

DEAERATOR

- OUTSIDE

SA 2.5

2P2 or 2 coats of Heat

resistant aluminium paint.

3) HEAT EXCHANGER

- INSIDE SA 2.5 -- -- --

- OUTSIDE SA 2.5 2P1 1N1 --

4) HEATER

Page 30 of 52





PAINTING SCHEME

(THERMAL CYCLE)

SURFACES TO BE

PAINTED

SURFACE

PREPARATI

ON

PAINTING SCHEME

PRIME

R AT

SHOP

INTER

M. AT

SHOP

FINISHI

NG AT

SITE

- INSIDE SA 2.5 -- -- --

- OUTSIDE SA 2.5 Heat

resistan

t

Aluminu

m paint

-- --

5) PUMPS SA 2.5 2P1/2P

2

1N1 2F1/2F

2

6) VENT

7) NON INSULATED

PIPELINE AND

VALVES

SA 2.5 2P1/2P

2/ 2P3

-- 2F1/2F

2/2F3

8) DRAINS, PIPELINE

AND VALVES TRAPS

ETC

- INSULATED SA 2.5 2P1/2P

2/ 2P3

-- --

- NON INSULATED SA 2.5 2P1/2P

2/ 2P3

-- 2F2

8) TANKS

- OUTSIDE SA 2.5 2P1/2P

2

-- --

- INSIDE -- -- -- --

Page 31 of 52





PAINTING SCHEME

(OIL + GAS-OIL CYCLE)

SURFACES TO BE

PAINTED

SURFACE

PREPARATI

ON

PAINTING SCHEME

PRIME

R AT

SHOP

INTERM.

AT

SHOP

FINIS

HING

AT

SITE

1) CLEAN / DIRTY OIL

TANK

- INSIDE SA 2.5 2P4 -- --

- OUTSIDE SA 2.5 2P1 1N1 2F1

2) PIPE LINE AND

VALVES


2

1N1 2F1/2

F2

- INSIDE -- -- -- --

3) PUMPS

- PUMPS SA 2.5 2P1 1N1 2F1

4) FILTERS


1

1N1 2F1/2

F2

- INSIDE

-- -- -- --

Page 32 of 52





PAINTING SCHEME

(CIRCUALATING WATER AND SERVICE WATER)

SURFACES TO BE

PAINTED

SURFACE

PREPARATI

ON

PAINTING SCHEME

PRIME

R AT

SHOP

INTERM

. AT

SHOP

FINISHI

NG AT

SITE

1) CONDENSER

- INSIDE

- OUTSIDE

SA 2.5

SA 2.5

--

2P1

--

1N1

--

2F1

- WATER BOX

AND TUBE

SHEET

SA 2.5 As per specification

Volume IIA

2) PUMPS SA 2.5 2P1 1N1 2F1

3) PIPELINE AND

VALVES

- INSIDE

- OUTSIDE (OVER

GROUND)

SA 2.5

SA 2.5

--

2P1

--

1N1

--

2F1

PAINTING SCHEME

(DEMINERALISED WATER)

Page 33 of 52




TG, Vol - IIA, Sec - XVII, Painting, NTA2 1

SURFACES TO BE

PAINTED

SURFACE

PREPARATI

ON

PAINTING SCHEME

PRIME

R AT

SHOP

INTERM

. AT

SHOP

FINISHI

NG AT

SITE

1) PIPELINE AND

VALVES

- INSIDE

- OUTSIDE

--

SA 2.5

--

2P1

--

1N1

--

2F1

2) PUMPS

- PUMPS

SA2.5

2P1

1N1

2F1

PAINTING SCHEME

(AIR CYCLE)

SURFACES TO BE

PAINTED

SURFACE

PREPARATI

ON

PAINTING SCHEME

PRIME

R AT

SHOP

INTERM

. AT

SHOP

FINISHI

NG AT

SITE

1) PIPE LINE AND

VALVES (SA)

- OUTSIDE

- INSIDE

SA 2.5

--

2P1

--

1N1

--

2F1

--

2) FILTERS /

STRAINERS

- OUTSIDE

SA 2.5

2P1

1N1

2F1

Page 34 of 52





PAINTING SCHEME

(AIR CYCLE)

SURFACES TO BE

PAINTED

SURFACE

PREPARATI

ON

PAINTING SCHEME

PRIME

R AT

SHOP

INTERM

. AT

SHOP

FINISHI

NG AT

SITE

- INSIDE -- -- -- --

Note : For Piping, Supports, Hangers, CLH, VLH & Other piping system components/ items

Painting Scheme as indicated in following table is also acceptable.

Page 35 of 52





Sl

.

N

o.

Description Surface

Preparation

& Surface

Profile

Primer Coat Finish Coat

Primer Coat No of

coats

& DFT

Paint No

of

coat

s &

DFT

Shade Total

DFT

Micro

ns

(Min.)

1 Insulated

Piping,

Component

s

(MS/HRH/C

RH/Aux

Steam

lines,………

)

SSPC-

SP3/Power

Tool

cleaning

Red oxide

Zinc

Phosphate

Primer (Alkyd

Base) to IS

12744

2

(30

micro

ns per

coat)

----- ----- ----- 60

2 Uninsulated

Piping,

component

s

(Condensat

e, Boiler

Filling,

HP/LP

dosing,

Lube oil,

Piping……..

)

Hand

Tool/Power

Tool

Cleaning to

SSPC-SP2

HB

Chlorinated

Rubber based

Red Oxide

Zinc

Phosphate

Primer

2

(50

micro

ns per

coat)

Chlorinated

Rubber

based finish

Paint

2

(30

micr

ons

per

coat

)

Smoke

Grey

Shade

No 692

of IS 5

160

3 Structures Hand

Tool/Power

Tool

Cleaning to

SSPC-SP2

HB

Chlorinated

Rubber based

Red Oxide

Zinc

Phosphate

2

(50

micro

ns per

coat)

Chlorinated

Rubber

based finish

Paint

2

(30

micr

ons

per

coat

Smoke

Grey

Shade

No 692

of IS 5

160

Page 36 of 52





Primer )

4 Hangers &

Supports-

(CLH,VLH)

Abrasive

Blast

cleaning to

Sa 2

(35-50

microns)

Epoxy Zinc

rich primer to

IS 14589

Gr.II,%

VS=35 Min

1

(40

micro

ns per

coat)

Aliphatic

Acrylic

Polyurethan

e paint, %

VS=40

min

1

(30

micr

ons

per

coat

)

Phirozi

Blue

Shade

No. 176

of IS 5

70

5 Pipe Clams SSPC-

SP3/Power

Tool

cleaning

Red oxide

Zinc

Phosphate

Primer (Alkyd

Base) to IS

12744

1

(30

micro

ns per

coat)

Synthetic

enamel

paint long

oil alkyd to

IS 2932

1

(20

micr

ons

per

coat

)

Smoke

Grey

Shade

No 692

of IS 5

70

6 Stainless

steel/Galva

nized items

No Paint No Paint No

Paint

No Paint No

Pain

t

No

Paint

No

Paint

17.3 Painting Of Steel Structural Works

17.3.1 All structural steel works covered in the civil scope in Volume V will be painted as

specified in Volume V (Design, Fabrication and erection of Structural steel works)

17.4 Submission Of Painting Schedule

Contractor will submit a comprehensive painting schedule indicating surface

preparation quality, paint applied, total DFT, colour code etc. for Customer/

consultant’s approval before the painting of any equipment/ component/ structure

etc.

Page 37 of 52


CHAIN PULLEY BLOCK

2X500 MW NNTPS (TG)


VOLUME - IIB

SECTION - D


PE

M-6

666-

0

SECTION – D

GENERAL TECHNICAL REQUIREMENTS

Page 38 of 52


CHAIN PULLEY BLOCK

2X500 MW NNTPS (TG)


VOLUME - IIB

SECTION - D


PE

M-6

666-

0

GENERAL

This specification covers the design, manufacture, assembly, painting, inspection and testing at manufacturer’s works of hand operated chain pulley block.

CODES AND STANDARDS

The design, manufacture, inspection and testing and performance of hand operated chain pulley blocks shall confirm to latest editions of the following standards : -

IS: 3832 Specification for hand operated chain pulley block.

IS 807:1976 Codes of Practice for Design, Manufacture, Erection and Testing (Structural Portion) of

cranes and hoists.

IS: 3109(Part II) Calibrated load chain for pulley blocks and other lifting appliances

IS: 2429(Part II) Calibrated hand chain for pulley blocks and other lifting appliances

IS: 4460 Method for rating of machine cut spur and helical gears

IS 6216 :1982 Short Link Chain, Grade T (8), Calibrated for Pulley Blocks and other Lifting Appliances

IS:15560: 2005 Point Hooks with Shank up to 160 Tonne - Specification

EQUIPMENT

Chain Pulley Block – The block shall be so designed that all components shall withstand without failure, an application to the block of a load equal to at least four times the working load limit.

Frame- Frame shall be robust in design and of welded construction .The frame shall be selected in such a way that head room requirement is minimum. Frame shall maintain alignment under all expected conditions of services.

Chain- The load chain shall be electrically welded, accurately calibrated, and pitched arid

polished conforming to IS: 6216 Grade 80(T8)/ IS 3109 (Part 2).

i. The load chain shall be electrically welded, accurately calibrated, and pitched arid polished conforming to IS: 6216 Grade 80(T8)/ IS 3109 (Part 2).

ii. The hand chain shall also be electrically welded, calibrated, pitched and polished and shall conform to IS: 2429 (Part II) Grade 30. The length of chain and link dimension shall be as per IS: 3832.

Hook The forged hook shall be properly heat treated and so designed that in loaded

condition, it is free to swivel without twisting the load chain. The hook shall conform to

IS: 15560

Reduction Gear- The reduction gear shall be either spur or worm/ worm wheel type. The spur gear and

worm shall be of high grade carbon steel and heat treated. The worm wheel shall be of

bronze. A detachable steel cover shall be provided for total enclosure of the gear train

Page 39 of 52


CHAIN PULLEY BLOCK

2X500 MW NNTPS (TG)


VOLUME - IIB

SECTION - D


PE

M-6

666-

0

and ample lubrication to be provided.

Brakes- Brakes shall be of screw friction disc type self-actuating or any other superior type.

Brake capacity shall be ample and humid atmosphere shall not affect materials used.

The brake shall prevent self-lowering of load and arrest and sustain load in all working

positions. The load brake shall also allow smooth lowering of the load without serious

overheating which may impair working of block

Bearing- Bearing used shall be as per guidelines laid down in IS: 3832.

Chain Wheels- The load chain wheel shall be made of heavy duty malleable casting and shall be

designed to ensure, effective operation of the chain. Load chain wheels shall be

mounted on two ball bearings. Hand chain wheel shall be made from malleable

casting/pressed sheet steel. The idler wheel shall be so shaped as to avoid the twisting

of the chain during operation. The P.C.D of idler wheels shall be such that the bending

action of the link is avoided. The hand chain wheel shall be provided with flanges and

designed to ensure effective operation with hand chain.

Trolley Monorail trolley frame shall be of heavy section rolled steel, held together by bolts.

Wheels shall be of high grade cast iron/steel mounted on ball bearings. Axles and

shafts shall be of carbon steel, accurately machined and suitably supported. The trolley

shall be suitable for variations in I section beams. The trolley shall be geared travel

type.

Other components- All other components of chain pulley block such as anchorage, guide, pawl, stripper

etc. shall be designed and provided as per IS: 3832.

The effort required for hoisting and travel shall be as stipulated in IS 3832.

Page 40 of 52


CHAIN PULLEY BLOCK

2X500 MW NNTPS (TG)


VOLUME - IIB

SECTION - D


PE

M-6

666-

0

DATA SHEET-A 1.00.0 Type : Hand operated chain pulley blocks 2.00.00 Capacity & Lift : As per Annexure I in Volume II B, Section C 3.00.00 Design : IS: 3832 4.00.00 Duty Class as per IS: 3832 : Class -II 5.00.00 Hoisting Mechanism a) Type : Hand operated gear transmission b) Load Chain : i) Type : Link type

ii) Material : Alloy steel grade 80 as per IS: 6216 / IS3109

iii) Conforms to (Std./Code): IS: 6216/3109 c) Hand Chain : i) Type : Link type ii) Material : Mild steel (grade 30) as per IS 2429 Part I d) Load Hook & Hook Block : i) Type of load hook : Plain shank- Trapezoidal section

ii) Load hooks conforms to: IS: 15560

iii) Type of hook suspension : Swiveling

iv) Type of make of bearing : Thrust ball bearing of hook suspension e) Gears / pinion :

i) Type : Spur / Helical

ii) Material : Alloy steel / carbon steel

iii) Type of bearing used : Antifriction ball bearing / Roller f) Sprockets

i) Type of bearings used : Antifriction ball bearing / Roller g) Method of lubrications Used

i) Bearings : Grease

ii) Gearing & Pinions : Grease

iii) Sprockets : Grease

Page 41 of 52


CHAIN PULLEY BLOCK

2X500 MW NNTPS (TG)


VOLUME - IIB

SECTION - D


PE

M-6

666-

0

h) Brakes :

i) Type : Screw and friction disc type 6.00.0 Trolley & Bridge Drive a) Trolley

i) Type : Geared (Manually operated)

ii) Material of frame : Rolled structural steel (IS:2062 Grade A or B) b) Drive Chain

i) Type : Link type ii) Material : Steel Gr.30 c) Trolley Wheel

i) Number of pairs of wheel : Two/four in each trolley/bridge ii) Flange : Single flanged iii) Wheel material : As per IS 3832 iv) Type of bearings need : Antifriction

d) Gears/ Pinions

i) Type : Spur / helical ii) Material : Alloy/ Carbon steel iii) Type of bearings used : Antifriction e) Method of lubrication for

i) Bearings : Grease ii) Sprockets : Grease

f) Load chain wheel

i) Material : As per IS 3832 g) Hand chain wheel

i) Material : As per IS 3832

SPECIFIC NOTE:

1. Ball and roller anti frictional bearing only will be used. Suitable greasing points will be provided. 2. Swiveling type standard shank hook mounted on grease lubricated anti-friction thrust bearing will be used.

Lifting hook will be solid, forged, heat treated alloy or carbon steel of rugged construction and provided with a standard depress type safety latch. Lock to prevent the hook from swiveling will be provided.

3. Load chain & operating chain will be of calibrated type as per relevant IS. The total length of the load chain will exceed the minimum length required to give the prescribed range of lift by not less than three links per fall to ensure that the slack end anchorage is not loaded. The load chain wheel will be of adequate strength Page 42 of 52


CHAIN PULLEY BLOCK

2X500 MW NNTPS (TG)


VOLUME - IIB

SECTION - D


PE

M-6

666-

0

and will be suitably designed to ensure effective operation of the chain and will be properly secured with shaft, preferably with splines.

4. Pulley used for the operating mechanism will have suitable guards to prevent the operating chain from coming out. The length of the hand chain will be such that the lowest point of the suspended loop will hang 400 mm above the operating level. Hand chain wheels will be provided with flanges and designed to ensure effective operation with hand chain. Minimum diameter of pulling chains will be 6 mm.

5. Gears will be cut from solid cast or forged steel blanks or will be of stress-relieved welded steel construction or built-up from steel billets and welded together to form a one piece gear section. All open gearing will be suitably covered.

6. The hoist will also conform to various safety codes as applicable at the place of installation. 7. Shafts and axles will have ample strength and rigidity and adequate bearing surface for the intended duties. 8. Pulleys used for operation mechanism will have suitable guards to prevent the operating chain from

covering off. 9. Brakes will be of automatic type that will stop and hold the load when hand-chain pull is released and will

permit controlled lowering of the load when hand-chain pull is applied in the lowering direction. 10. Pawls will be of sufficient strength to arrest the full load from lowering due to gravity. The pawl and ratchet

wheel will be of steel, hardened and tempered so as to attain required wear resistance and toughness.

Page 43 of 52


CHAIN PULLEY BLOCK

2X500 MW NNTPS (TG)


VOLUME – II B

SECTION D


PE

M-6

666-

0

Annexure- V

Master drawing list and submission schedule Sl. No.

BHEL DRG.NO DRAWING TITLE REMARKS SUBMISSION SCHEDULE - WEEK NUMBER FROM DATE OF P.O

1 PE-V0-402-563-A200 Manufacturing

Quality Plan APPROVAL 2

2

PE-V0-402-563-A201 GA Drawing for Chain Pulley Block with detail BOM with painting details

APPROVAL 2

3 PE-V0-402-563-A202 O & M Manual INFORMATION 4 4 PE-V0-402-563-A204 Erection procedure INFORMATION 4 NOTE 1. VENDOR SHALL RESUBMIT THE REVISED DRAWINGS WITHIN 7 DAYS OF RECIEPT OF

COMMENTS. 2. INCOMPLETE DRAWINGS/DOCUMENTS SHALL NOT BE TREATED AS SUBMITTED. 3. MANUFACTURING SHALL BE STARTED ON RECIEPT OF CAT II APPROVED DRAWINGS. Note: 1.0 Bidder to note that all the drawings and documents shall also be submitted on CD’s (compact disc) in following software. a) All the drawings shall be prepared in AutoCAD. b) All the documents shall be prepared MS word / EXCEL. c) PDF files for all drawings/documents shall also be submitted. Document Management System Bidder to note that BHEL reserve the right for drg/doc submission through web based Document Management System. Bidder would be provided access to the DMS for drg/doc approval and adequate training for the same. Detailed methodology would be finalized during the kick‐off meeting. Bidder to ensure following at their end. Internet explorer version – Minimum Internet Explorer 7 Internet speed – 2 mbps (Minimum preferred) Pop ups from our external DMS IP (124.124.36.198) should not be blocked. Vendor’s Internal proxy setting should not block DMS application’s link (http://124.124.36.198/wrenchwebaccess/login.aspx)”.

Page 44 of 52


CHAIN PULLEY BLOCK

2X500 MW NNTPS (TG)


VOLUME – II B

SECTION D


PE

M-6

666-

0

Page 45 of 52


CHAIN PULLEY BLOCK

2X500 MW NNTPS (TG)


VOLUME - III

SECTION - D


PE

M-6

666-

0

VOL -III

Page 46 of 52


CHAIN PULLEY BLOCK

2X500 MW NNTPS (TG)


VOLUME - III


PE

M-6

666-

0

PRE-BID CLARIFICATION SCHEDULE

S. No. Section/Clause/Page No.

Statement of the referred clause

Clarification Required

The bidder hereby certifies that above mentioned are the only clarifications required on the technical specification for the subject package.

SIGNATURE: ___________________ NAME: _________________________ DESIGNATION: __________________ COMPANY: _____________________ DATE: __________________________

COMPANY SEAL

Page 47 of 52

SL NO

VOULME/ SECTION

PAGE NO.

CLAUSE NO.TECHNICAL

SPECIFICATION/ TENDER DOCUMENT

COMPLETE DESCRIPTION OF DEVIATION

COST OF WITHDRAWL

OF DEVIATION

REFERENCE OF PRICE SCHEDULE ON WHICH COST

OF WITHDRAWL OF DEVIATION IS APPLICABLE

NATURE OF COST OF WITHDRAWL OF DEVIATION

(POSITIVE/ NEGATIVE)

14. In case of descrepancy in the nature of impact (positive/ negative), positive will be considered for evaluation and negative for ordering.

8. Bidders to note that any deviation (technical/commercial) not listed in above and asked after Part-I opening shall not be considered.

9. For deviations w.r.t. Payment terms, Liquidated damages, Firm prices and submission of E1/ E2 forms before claiming 10% payment, if a bidder chooses not to give any cost of withdrawl of deviation loading as per Annexure-VIII of GCC, Rev-06 will apply. For any other deviation mentioned in un-priced copy of this format submitted with Part-I bid but not mentioned in priced copy of this format submitted with Priced bid, the cost of withdrawl of deviation shall be taken as NIL.

10. Any deviation mentioned in priced copy of this format, but not mentioned in the un-priced copy, shall not be accepted.

11. All techno-commercial terms and conditions of NIT shall be deemed to have been accepted by the bidder, other than those listed in unpriced copy of this format.

12. Cost of withdrawl is to be given seperately for each deviation. In no event bidder should club cost of withdrawl of more than one deviation else cost of withdrawl of such deviations which have been clubbed together shall be considered as NIL.

13. In case nature of cost of withdrawl (positive/negative) is not specified it shall be assumed as positive.

2. For directly dispatchable items, cost of withdrawl of deviation will be applicable on the basic price including taxes, duties & freight.

3. All the bidders have to list out all their Technical & Commercial Deviations (if any) in detail in the above format.

4. Any deviation not mentioned above and shown separately or found hidden in offer, will not be taken cognizance of.

5. Bidder shall submit duly filled unpriced copy of above format indicating "quoted" in "cost of withdrawl of deviation" column of the schedule above along with their Techno-commercial offer, wherever applicable.

6. Bidder shall furnish price copy of above format along with price bid.

7. The final decision of acceptance/ rejection of the deviations quoted by the bidder shall be at discretion of the Purchaser.

NAME DESIGNATIONS SIGN & DATE

NOTES:

1. For self manufactured items of bidder, cost of withdrawl of deviation will be applicable on the basic price (i.e. excluding taxes, duties & freight) only.

PARTICULARS OF BIDDERS/ AUTHORISED REPRESENTATIVE

COMMERCIAL DEVIATIONS

TECHNICAL DEVIATIONS

VOLUME IIIDEVIATION SHEET (COST OF WITHDRAWAL)

PROJECT:- 2X500 MW NNTPS (TG)

PACKAGE:- Chain Pulley Blocks, SPECIFICATION NO.: PE-TS-402-563-A001

TENDER ENQUIRY REFERENCE:-

NAME OF VENDOR:-

REASON FOR QUOTING DEVIATION

Page 48 of 52

TITLE: TECHNICAL SPECIFICATION

2X500 MW NNTPS (TG) COMPLIANCE CUM CONFIRMATION

CERTIFICATE

SPEC. NO.: PE-TS-402-563-A001 VOLUME: III SECTION: REV. NO. 0

COMPLIANCE CUM CONFIRMATION CERTIFICATE The bidder shall confirm compliance with following by signing/ stamping this compliance certificate (every sheet) and furnish same with the offer.

a) The scope of supply, technical details, construction features, design parameters etc. shall be as per technical specification & there are no exclusions other than those mentioned under “exclusion” in section C and those resolved as per ‘Schedule of Deviations’, if applicable, with regard to same.

b) There are no other deviations w.r.t. specifications other than those furnished in the ‘Schedule of

Deviations’. Any other deviation, stated or implied, taken elsewhere in the offer stands withdrawn unless specifically brought out in the ‘Schedule of Deviations’.

c) Bidder shall submit QP in the event of order based on the guidelines given in the specification & QP enclosed therein. QP will be subject to BHEL/ CUSTOMER approval & customer hold points for inspection/ testing shall be marked in the QP at the contract stage. Inspection/ testing shall be witnessed as per same apart from review of various test certificates/ Inspection records etc. This shall be within the contracted price with no extra implications to BHEL after award of the contract.

d) All drawings/ data-sheets/ calculations etc. submitted along with the offer shall be considered for reference only, same shall be subject to BHEL/ CUSTOMER approval in the event of order.

e) The offered materials shall be either equivalent or superior to those specified in the specification & shall meet the specified/ intended duty requirements. In case the material specified in the specifications is not compatible for intended duty requirements then same shall be resolved by the bidder with BHEL during the pre - bid discussions, otherwise BHEL/ Customer’s decision shall be binding on the bidder whenever the deficiency is pointed out.

f) For components where materials are not specified, same shall be suitable for intended duty, all materials shall be subject to approval in the event of order.

g) The commissioning spares shall be supplied on ‘As per technical specification’ (if applicable) & prices for same included in the base price itself.

h) All sub vendors shall be subject to BHEL/ CUSTOMER approval in the event of order.

i) Guarantee for plant /equipment shall be as per relevant clause of GCC /SCC /Other Commercial Terms & Conditions.

j) In the event of order, all the material required for completing the job at site shall be supplied by the bidder within the ordered price and within purview of the contract specification even if the same are additional to approved billing break up, approved drawing or approved Bill of quantities.

k) Schedule of drawings submissions, comment incorporations & approval shall be as stipulated in the

specifications. The successful bidder shall depute his design personnel to BHEL’s/ Customer’s/ Consultant’s office for across the table resolution of issues and to get documents approved in the stipulated time.

l) As built drawings shall be submitted as and when required during the project execution.

m) The bidder has not tempered with this compliance cum confirmation certificate and if at any stage any tempering in the signed copy of this document is noticed then same shall be treated as breach of contract and suitable actions shall be taken against the bidder.

Page 49 of 52


CHAIN PULLEY BLOCK

2X500 MW NNTPS (TG)


VOLUME - III


PE

M-6

666-

0

Annexure VI DOCUMENTS TO BE FURNISHED WITH OFFER FOR TECHNICAL EVALUATION

1) SCHEDULE OF TECHNICAL DEVIATION ( IF ANY) along with mention of “QUOTED” in front of each

deviation in the specified column.

OR ‘NO DEVIATION CERTIFICATE’ – Clearly mentioning that bidder has considered ‘No - Deviation’ from the technical specification provided by BHEL.

2) SIGNED AND STAMPED COPY OF COMPLIANCE CUM CONFIRMATION CERTIFICATE. 3) Unpriced schedule, duly mentioned ‘Quoted’ against each Sl.no. below each column.

NOTE: i) NO OTHER DOCUMENTS OTHER THAN THOSE LISTED ABOVE ARE REQUIRED TO BE S UBMITTED FOR TECHNICAL EVALUATION. IN CASE ANY OTHER DOCUMENT IS FURNISHED, THE SAME WILL NOT BE TAKEN INTO CONSIDERATION FOR TECHNICAL EVALAUATION. ii) BIDDER TO CLEARLY MENTION “QUOTED” AGAINST EACH ITEM. IN CASE ANY ITEM IS NOT APPLICABLE THEN “NA” SHOULD BE CLEARLY MENTIONED AGAINST THE SAME.

Page 50 of 52

Sl No.

Description of equipment / item Total quantity required

Total Price (Ex-works) i.e. (3 x 4)

ED CST FREIGHT INSURANCE TOTAL ( FOR SITE) (5+6+7+8+9)

(1) (2) (3) (4) (5) (6) (7) (8) (9)

1.0 Total lumpsum firm price for design, engineering, manufacture, inspection and testing atvendor's’/ sub-vendor’s works, painting, forwarding, proper packing and shipment and deliveryat site as required on FOR site basis, demonstration test at vendor’s works including freight,for the following chain pulley blocks along with 1 Set of Maintenance tools & tackles (as perannexure-I) and all other accessories in line with drawings/ documents/ test proceduresapproved by BHEL/Customer for the total scope given below and technical parameters as pertechnical specification PE-TS-402- 563-A001 taking into account all clarifications,confirmations and agreements till date.

25 no.s

Break-up of 1.0 (1.1 to 1.14)

1.1 11 no.s 2T cap, 6 M lift chain pulley block with travelling trolley for following areas-a) AHU room at 8.5m floor (1 no.)b) AHU room at each floor of service building (10 no.s)

11 No.s

1.2 9 no.s 2T cap, 8.5 M lift chain pulley block with travelling trolley for following areas-a) AHU ROOM AT 24 M (1 no.)b) AIR WASHER ROOM-1 (2 no.s)c) AIR WASHER ROOM-2 (2 no.s)d) AIR WASHER ROOM-3 (2 no.s)e) AIR WASHER ROOM-4 (2 no.s)

9 No.s

1.3 5 no.s 1T cap, 10 M lift chain pulley block with travelling trolley for following areas-a) TG BLDG. Sump Pumps (4 no.s)b) Lube Oil Unloading IN B-C Bay (1 no.)

5 no.s

1.4 Total lumpsum firm price for one set of Maintenance Tools and Tackles as per Annexure A 1 set

(Bidder's Signature with Company Seal)

In case, price indicated above does not match with the total of item wise break-up given from 1.1 to 1.4 the highest price so calculated shall be considered for evaluation but in case of order, the same shall be placed at the lowest price.

Project: 2X500 MW NNTPS (TG)

SUGGESTIVE PRICE FORMAT CHAIN PULLEY BLOCK

Bidder to note that total price indicated above at 1.0 shall be considered for evaluation and hence should be complete in all respect for the full scope defined and considering all terms and conditions agreed.Any item not included in the price quoted above and shown separately will not be taken cognizance of and the offer shall be liable for rejection.

Page 51 of 52

Sl.no Description Unit Unit Ex-works price

Total ex-works price

ED CST FREIGHT Total

1 2 3 4 5 6 7 8 4 to 81 Adjustable spanner 1 Set2 Wrench spanner 1 Set3 Oil gun 1 No. 4 Set of Screw driver Min 6 nos. (of

different sizes suiting various types and capacities of Chain Pulley Blocks)

5 2 lb hammer with wooden handle

1 No.

6 Grease Gun 1 No.

7 Any other item required for maintenance

As per vendorrecommendation

Date: ________________

Company SealBidder's / bidder's representative signature

Note: - The tools shall be supplied in one tool box

ANNEXURE-A

List of Maintenance Tools & Tackles

Project: 2X500 MW NNTPS (TG)PACKAGE:- Chain Pulley Blocks, SPECIFICATION NO.: PE-TS-402-563-A001

Page 52 of 52

NEYVELI LIGNITE CORPORATION LIMITED (NLC LTD) · PDF filetechnical specification for chain...

Documents

Transcript of NEYVELI LIGNITE CORPORATION LIMITED (NLC LTD) · PDF filetechnical specification for chain...